Electric arc welding torch



March 23, 1943. v H, PAvLEcKA ELECTRIC ARC WELDING Tonga Filed Oct. 6, 1941 IAWENTORT hh W @wfg E VLAD/M//P H. PAVLECKA.

ATTORNEYS.

Patented Mar. 23,1943

2.314.628 Alto WELDING Tonen Y ELEc'rnro oFFicE Vladlmirfl-I. Pavlecka, Pacino Palisades. Calif., as

signor to Northrop Aircraft,l Inc., Hawthorne, Calif.. a corporation of California Appiioaiion oeioberc, 1941,.:seria1 No. 41am 13 Clahnl. (Cl. 21S-15) My invention relates to electric arc welding torches and more particularly to a welding torch adapted for use in welding low melting point materials, such as aluminum and magnesium or the alloys thereof, in commotion with a helium gas arc blanket. This invention embodies improvements on the arc welding torch, shown, described and claimed in the co-pending Meredith application Serial No. 373,157, filed January 4, 1941. entitled Welding torch and since matured into Patent No. 2,274,631, dated February 24, 1942.

In the application Just above cited it has been pointed out that electric arc welding using a refractory rod for one electrode. and the work for the other electrode, can be very satisfactorily carried out in conjunction with the welding of aluminum and magnesium sheets, when a iiow of helium gas at low pressure is directed over the arc zone, and when precautions are taken to pre-l vent atmospheric air from entering the helium blanket.

Meredith lprevents atmospheric` air from being drawn into the arc by supplying the gas through a: tube out of which the refractory electrode concentrically projects, and flaring the end of. this tube to divert air drawn down the outside ofthe tube away from the arc zone. This torch has been found to be very suocessfulin arc welding magnesiumsheet.

The present application provides a'torch embodying additional features to'control theproper ilow oi' helium gas around the arc during the operation. provides a torch in which a minimum of refractory electrode is wasted, and provides a simple and eiilcient arc welding torchA construction including means for directing helium gas or the like to the arc zone without substantlalturbulence.

Y Other objects of my invention will be aiiparent'l or will be specifically pointed out in the des crip.v

for reducing waste in the use of refractory electrode material. Y

Fig. 3 is a sectional view taken as indicated by the line 3 3 in Fig. 2.

Fig'. 4 is a sectional view taken as indicated by the line 4 4 of Fig.` 2.

Fig. 5 is a sectional view of the handle taken as indicated by line 5-5 in Fig. 2.

In the Meredith application cited above a torch having an'end portion similar in general construction to that shown in Fig. 1, is utilized to weld aluminum, magnesium or alloys thereof in sheet or solid form by applying current through a refractory electrode. such as a tungsten rod. to the weld area. striking an arc, and feeding filler material into the arc while flowing helium gas at a low pressure at, for example, .36 pound per square inch. The gas is supplied axially around the tungsten electrode, into the arc zone and around the weld material. In this manner a simple structure can be used for welding and blanketing an arc with gas during welding, oxidation of the weld is prevented, and danger of igniting the materials having relatively low melting and ignition points is removed.

InFig. 1 I have shown a sectional view of the tip portion of a Meredith type torch with an additional construction embodied therein to tion forming a part of thls'speclilcation, but I o donut limit myselfto the embodiment of theA invention herein described. as various forms may be adopted within the scope of the claims.

In the drawing: p Fig. i is a sectional view of an arc welding torch utilizing the generalconstruction of the Meredith 'torch above referred to, together with 5'0 an expansion chamber `for reducing turbulence in the gas delivered to the arc zone. l

F18. 2 is a longitudinal sectional view of a com-- plete torch embodying turbulence'control in the supplying of gas to the arc zone. and a means u prevent turbulence of the gas supplied to the arc zone, and I will firstdescribe this embodiment of my invention.

In this casea helium conduit i` is provided, attachedvto a tip-body 2. Helium'conduit l may be utilized as a handle for torch if desired. 'Ilp-body 2 is provided with an expansion chamber l axially formed therein, and a ,threaded end 4 to which is attached a nozzle 5 terminating in a flared end 6. The

other end of tip-body 2 is provided with threads 8 to which a retaining cap 9 is screwed, this retaining cap 9 positioning and fastening a bushing I0 to body 2 by forcing shoulder il on l the bushing against the end of the body by means of a washer l2. Bushing I 0 is` provided with a split tapered end I3 which can be tightened against a tungsten electrode rod Il by the use of a wedge nut I5.

flared. end 8. The arc flared end t and the work, and helium at a relatively low pressure, say of .36 or less pound manipulating the The tungsten electrode n .y i4 is positioned to extend axially through ex` pansion chamber l and beyond flared end B. in

such a manner that 'a narrow annular duct AIl is provided between expansion chamber l and is maintained between l the end of tungsten electrode il projecting from per square inch, is ilowed through helium duct I, into expansion chamber 3, from which it flows strictly axially and without turbulence around the electrode I3 to the arc zone. The expan sion chamber 3 in the torch rectifies the flow, distributes the helium uniformly around the electrode I3 and completely eliminates irregular ilow which can occur when no expansion chamber 3 is utilized in thehelium line. The narrow peripheral space around the tungsten yelectrode confines the helium to a strictly axial flow which is not substantially disturbed in passing through the ared end 3, so that the gas reaches the arc zone substantially uncontaminated by atmospheric air and substantially as a tubular uniform ilow.

In the type of torch just above described, there is some loss of tungsten during the welding process and therefore the tungsten rod I3 occasionally is fed through the tip so that it projects the proper amount from the flared end, by loosening nut i3 thus freeing the rod, movlng the rod toward the flared end and then locking the rod in place again by screwing nut i5 against tapered end I3.

However, it will be obvious that once the outer end of the tungsten rod I4 has reached the tapered end I3 the rod can no longer be fed through the device. The tungsten rod then must be discarded and a longer rod substituted. This results in the loss of a considerable length of tungsten rod.

I have therefore provided a modified construction wherein the tungsten rod can be used to a much greater extent. Such a torch is shown in complete detail in Figs. 2, 3 and 4. This torch also embodies the axial ow principle described in conjunction with Fig. 1.

In this case the torch is provided with a hollow handle 33 having exterior ridges 3| to ald hand grasp, and for raising the hand away from perfect contact with the handle, to avoid sweating. The handle is split longitudinally. One end thereof is provided with one half of channel 32 for the passage of a power wire 33, and with one half of parallel channel 3l for the passage of a helium tube 35. The handle halves are held together at this end of the handle by a spring ring 3,6 surrounding both halves.

The other end of the handle is provided with an axial channel 31 for the reception of a composite hollow stem 38. This stem 33 comprises' 3| in the interior of the handle. At the stem j Y end of the handle, the handle halves are locked together by second spring ring 32.

Within chamber 4i the external insulating tube terminates so that an electrical connection clamp 33 may be attached to the inner metallic tube 33. This clamp is in turn attached to the end of electrical power wire 33, as shown in Fig. 4.

The inner end of metallic tube 33 is attached through an insulating sleeve 33' to a thumb valve body 50 having therein a plunger Moperated from outside the handle by a thumb button 52. Valve 53 controls the ilow ofgas from helium tube 33 into the metallic portion 33 of stem 38, helium tube 35'being connected to the inlet of valve body. 53. Thumb valve 32 is` normally maintained closedby spring 33. Plunger 5l operates through the usual stumng box 56. Thumb valve body 30 is held-in place within the handle by having its ends register with recesses 31 in opposite halves of 'the handle.

The handle isi provided with a soft rubber shield 33 curved backwards over part of thumb button s2, this shield being sprung into annular shield recess 3lk cut in the two halves of the handle. Thus the rubber shield 33 also serves to hold the handle parts together. Shield 33 is preferably of soft rubber, extends sumciently laterally to protect the hand of the operator from theultra-violet rays and heatv emitted by the arc, and is sufllciently resilient so that if it contacts the work the shield will give without damaging the work.`

Composite stem 33 is extended outwardly from handle 33 a distance-to placethe operating end of the torch in proper position to be seen and moved by the operator of the torch, and terminates in' anelectrode end, which will next be described.

Brazed to the end of the metal tube portion 33 of stem 33 is an inner metal tip portion 32 extending forward and then downwardly with relation to the position of thumb button 32. This `tip portion 32 is provided with an interior bore 33 registering with and of substantially the same diameter as the interior of the metal tube 33 to which it is brazed. The end of tip 32 is provided with an axial tapered bore 33 surrounded by lateral parallel bores 66 as shown in Fig. 5. The central bore 83 receives, with a press fit, a relatively short tungsten electrode 33.

Thus it can be seen that gas may now from helium tube 33, through valve 33 through the interior of metal tube 33, through the bore 33 of tip 32 and through lateral bores 33 to emerge in axial ilow around the short electrode 33. It can also be seen that electric current will be conducted through power wire 33, through connection 33 into tube 33 and thence from .tube 33 and tip 32 into electrode 33. Thus tube 33 not only carries the helium flow, but also carriesthe welding current.

On the handle side of the welder between `tip 32 and metal tube 33, an exterior sleeve." is press-fitted over `composite steam 33, with the insulating tubing 33 terminating just under the and are Vheldin exact alinement through the use of tip insulatingsleeve 1l.

vTip sleeve 13 at its 4lower end is provided with threads" to which vis screwed a nozzle 11 terminating ina flared endv 13 similar in contour and function to flared end 3 in' Pig. 1and tothe flared end used inthe Meredithtorch. .Pas-

' tened to .tip sleeve 13 is a circumferential split end of nozzle 11.

sleeve", the split portions extending downwardly over. threads 13 yand over the engaged This split sleeve 33 is split longitudinally so that the tongues thereof will apply pressure to the engaged end of nozzle 11 so that as the nozzle is screwed on threads 13, the nozzle will stay in` position as left, without danger ot being accidently displaced:

v This completes the description ofthe mechanical features of the torch, and I will scribe its operation.

next 'deplate having a weld channel 84 cut therein following the extent oi the weld to be made. The

work sheets 8i and 82 and copper backing platefA t6 are connected through return power line 8i to a generator of electrical power 86, the other connection of which is made to power wire Il entering handle I0. A fresh tungsten electrode 66 is then inserted in bore $4 and the nozzle I'l is screwed outwardly until the flared end 'I8 is in proper relationship to the outer end of electrode 68 to direct the helium therearound. Helium gas is supplied to helium pipe from a helium tank 00 provided with the usual valves and pressure gauge assembly 9| and the device is ready for operation.

The handle is grasped by the operator and helium at a low pressure, on the order of .36 pound per square inch, for example, is released into metal pipe 39 by pressure on thumb button 52. As soon as helium is ilowing properly the end of electrode 6B is touched to the work, the arc established and the weld made by feeding material to the weld from a ller rod not shown. This ller rod may be of the same material as sheets 8l and 82 such as, for example, magnesium, aluminum or alloys thereof, or any other metal alloys, e. g., InconeL stainless steel, brasses, copper alloys, etc., with which very excellent welds have been obtained by this method. Helium gas is relatively expensive and even il' used at the low pressures as recited, conservation is valuable. Thumb valve therefore need only be used to admit helium to the tip when actually needed for the welding. At all other times the valve may remain closed. l .l

As the helium is being applied tothe arc the interior of the metal tube 39 and the tip bore." acts in the same manner as expansion chamber l in the device shown in Fig. 1. The flow o! helium emerges in strictly axial ilow i'rom'bores IB, and the gas flows from these bores without turbulence along the electrode 86 to'the arc. Irregular flow is eliminated as inthe device of Pig. l, and the helium is uniformly distributed around the electrode, the arc and the weld without substantial inclusion of atmosphericair.

It will be noted that in the constructionv just acterlstics of the Meredith torch, and of the torch shown in Fig. i. j

I claim:

l. An electric arc welding torch including a refractory electrode rod, a tube concentrically positionedaroundsaidrodandhavingaiiared metal end beyond which said rod projects, the interior oi said tube being constricted directly around said rod as said rod enters said ilared end then expanded, and again constricted around said rod as said rod leaves said flared end to form an expansion chamber in said end, and means for supplying an arc blanket gas to said tube above said constriction, whereby said gas will flow through the expansion chamber in said iiared end and around the projecting end of said Vrod substantially without turbulence.

2. Apparatus in accordance with claim l. wherein said tube and said rod are insulated from each other.

3. Apparatus in accordance with claim. 1 wherein the interior of said tube is expanded immediately prior to the first recited constriction thereof to form another expansion chamber ilrst traversed by said gas.

4. Apparatus in accordance with claim 1 wherein the cross section at said first recited constriction isannular.

5. Apparatus in accordance with claim 1 wherein the cross section at said irst recited constriction is constricted by dividingsaid conduit in'to a plurality of openings circumferentially positioned around said electrode.

6. An arc welding torch comprising an electrically conductive gas conduit, an electrode axially inserted in the end face of said conduit, saidv conduit having aplurality of separate bores in said end face circumferentially surrounding `said electrode at the insertion thereof, and difrected axially along the periphery of said elec-f trode.' means for electrically connecting said conduit to a-source of electrical power suitable fork arc welding,'means for supplying an arc blanketing gas to the interior oi' said conduit, and an air shield- Vmounted concentrically around l said conduit to form an expansion chamberfsurroundingl saidend face, and-a portion of said electrode, said chamber terminating in a conl stricted annular opening around said electrode described, the electrode ,il is relatively short.

Inasmuch as this electrode gradually absorbs gas at high temperature during use, and thereby becomes brittle, it periodically breaks oil at the tip due to mechanical shocks, e. g., dropping the torch on a work-bench. The distance between the end of the electrode 66 and flared end 18 will Itherefore gradually become shorter. When this distance becomes too short for proper operation of the torch, nozzle 'Il may be screwed inwardly on tip sleeve i4 so that the proper length of electrode 66 may again project beyond ilared end 1I. This procedure can be continued until nozzle 11 is retracted as far as possible on tip sleeve 14. At this time the end of electrode 85 will be very close to the end of tip portion 80. and the small remainder of electrode 86 may be removed from the tip portion 80, discarded, and

a new electrode inserted.

Thus I have provided in the torch shown in Figs. 2 to 4, inclusive, a helium arc welding torch, in which there is very small loss of the refractory electrode material and yet which will with the end voi said electrode projecting beyond vsaid opening.

7. An arc welding torch lcomprising an electrically conductive gas conduit, an electrode axially inserted in the end of said conduit, the inhave at the same time all of the desirable charterior walls of said conduit having a plurality of axially directed channels therein separated by the insertion of said electrode, said channels forming the end outlet from the interior of said conduit, means for electrically connecting said conduit to a source of electrical power suitable for arc welding, and means for supplying an arc blanketing gas to the interior of said conduit.

8. An arc welding torch comprising an electrically conducting gas conduit, an' electrode axially inserted in the end lface of said conduit, said conduit having a plurality of separate bores in said end face circumferentially surrounding said electrode at the insertion thereof, and directed axially along the periphery of said electrode, means for electrically connecting said conduit to a source of electrical power suitable for arc welding, means for supplying an arc blanketing gas to the interior of said conduit, and an outwardly aring air shield mounted concentrically with respect to said conduit and projecting beyond said end face, the interior ofA said shield being expanded adjacent said end face and terminating in a constricted annular opening through which the end of said electrode projects.

9. An arc welding torch comprising an electrically conductive gas conduit, an electrode axially inserted in the end of said conduit, said conduit having a plurality of bores in said end circumferentially surrounding said electrode at the insertion thereof and directed axially along the periphery of said electrode, means for electrically connecting said tube to asource of electrical power suitable for arc welding, and an outwardly ilaring air shield mounted concentrically with respect to said tube adjacent the end thereoi with said electrode projecting beyond the open end thereof, said shield being axially movable with respect to said tube to compensate for changes in electrode length.

l0. An arc welding torch comprising an electrically conductive gas conduit, an electrode axially inserted in the end of said conduit, said conduit having a plurality ot bores in said end circumferentially surrounding said electrode at the insertion thereof and directed axially along the periphery of said electrode, means for electrically connecting said tube to a source of electrical power suitable for arc welding, and an outwardly flaring air shield mounted concentrically with respect to said tube adjacent the end thereof with said electrode projecting beyond theA open end thereof, said shield being mounted on threads attached to said tube for diierential axial placement thereof with respect t0 the end of said electrode.

asuma 11. An arc welding torch comprising an electrically conductive gas conduit. an electrode axially inserted in the end oi' said conduit. said conduit having a plurality oi bores in said end circumferentially surrounding said electrode at t-he insertion thereof and directed axially l10n! the periphery of said electrode, means ior electrically connecting said tube to a source oi electrical power suitable for arc welding. and an outwardly ilaring air shield mounted ooncentrically with respect to said tube adjacent the end thereof with said electrode projecting beyond the open end thereof, said shield being insulated from said tube.

l2. Apparatus in accordance with claim 9 wherein said tube is angular-ly extended to enter a handle, and a thumb operated valve is positioned in said handle and connected w said tube and gas supply to control said gas and wherein said electrical power connection is made to said tube inside of said handle prior to the connection of said tube to said valve.

VLADIMIR H. PAVLECKA. 

